Production of aromatics from a methane conversion process

ABSTRACT

Methods and systems are provided for converting methane in a feed stream to acetylene. The hydrocarbon stream is introduced into a supersonic reactor and pyrolyzed to convert at least a portion of the methane to acetylene. The reactor effluent stream may be treated to convert acetylene to a process stream having aromatic compounds. The acetylene stream can be reacted to generate larger hydrocarbon compounds, which are passed to a cyclization and aromatization reactor to generate aromatics. The method according to certain aspects includes controlling the level of carbon oxides in the hydrocarbon stream.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority from Provisional Application No.61/691,373 filed Aug. 21, 2012, the contents of which are herebyincorporated by reference in its entirety.

FIELD OF THE INVENTION

A process is disclosed for producing chemicals useful for the productionof polymers from the conversion of methane to acetylene using asupersonic flow reactor. More particularly, the process is for theproduction of aromatics.

BACKGROUND OF THE INVENTION

The use of plastics and rubbers are widespread in today's world. Theproduction of these plastics and rubbers are from the polymerization ofmonomers which are generally produced from petroleum. The monomers aregenerated by the breakdown of larger molecules to smaller moleculeswhich can be modified. The monomers are then reacted to generate largermolecules comprising chains of the monomers. An important example ofthese monomers are light olefins, including ethylene and propylene,which represent a large portion of the worldwide demand in thepetrochemical industry. Light olefins, and other monomers, are used inthe production of numerous chemical products via polymerization,oligomerization, alkylation and other well-known chemical reactions.Producing large quantities of light olefin material in an economicalmanner, therefore, is a focus in the petrochemical industry. Thesemonomers are essential building blocks for the modern petrochemical andchemical industries. The main source for these materials in present dayrefining is the steam cracking of petroleum feeds.

A principal means of production is the cracking of hydrocarbons broughtabout by heating a feedstock material in a furnace has long been used toproduce useful products, including for example, olefin products. Forexample, ethylene, which is among the more important products in thechemical industry, can be produced by the pyrolysis of feedstocksranging from light paraffins, such as ethane and propane, to heavierfractions such as naphtha. Typically, the lighter feedstocks producehigher ethylene yields (50-55% for ethane compared to 25-30% fornaphtha); however, the cost of the feedstock is more likely to determinewhich is used. Historically, naphtha cracking has provided the largestsource of ethylene, followed by ethane and propane pyrolysis, cracking,or dehydrogenation. Due to the large demand for ethylene and other lightolefinic materials, however, the cost of these traditional feeds hassteadily increased.

Energy consumption is another cost factor impacting the pyrolyticproduction of chemical products from various feedstocks. Over the pastseveral decades, there have been significant improvements in theefficiency of the pyrolysis process that have reduced the costs ofproduction. In a typical or conventional pyrolysis plant, a feedstockpasses through a plurality of heat exchanger tubes where it is heatedexternally to a pyrolysis temperature by the combustion products of fueloil or natural gas and air. One of the more important steps taken tominimize production costs has been the reduction of the residence timefor a feedstock in the heat exchanger tubes of a pyrolysis furnace.Reduction of the residence time increases the yield of the desiredproduct while reducing the production of heavier by-products that tendto foul the pyrolysis tube walls. However, there is little room left toimprove the residence times or overall energy consumption in traditionpyrolysis processes.

More recent attempts to decrease light olefin production costs includeutilizing alternative processes and/or feedstreams. In one approach,hydrocarbon oxygenates and more specifically methanol or dimethylether(DME) are used as an alternative feedstock for producing light olefinproducts. Oxygenates can be produced from available materials such ascoal, natural gas, recycled plastics, various carbon waste streams fromindustry and various products and by-products from the agriculturalindustry. Making methanol and other oxygenates from these types of rawmaterials is well established and typically includes one or moregenerally known processes such as the manufacture of synthesis gas usinga nickel or cobalt catalyst in a steam reforming step followed by amethanol synthesis step at relatively high pressure using a copper-basedcatalyst.

Once the oxygenates are formed, the process includes catalyticallyconverting the oxygenates, such as methanol, into the desired lightolefin products in an oxygenate to olefin (OTO) process. Techniques forconverting oxygenates, such as methanol to light olefins (MTO), aredescribed in U.S. Pat. No. 4,387,263, which discloses a process thatutilizes a catalytic conversion zone containing a zeolitic typecatalyst. U.S. Pat. No. 4,587,373 discloses using a zeolitic catalystlike ZSM-5 for purposes of making light olefins. U.S. Pat. Nos.5,095,163; 5,126,308 and 5,191,141 on the other hand, disclose an MTOconversion technology utilizing a non-zeolitic molecular sieve catalyticmaterial, such as a metal aluminophosphate (ELAPO) molecular sieve. OTOand MTO processes, while useful, utilize an indirect process for forminga desired hydrocarbon product by first converting a feed to an oxygenateand subsequently converting the oxygenate to the hydrocarbon product.This indirect route of production is often associated with energy andcost penalties, often reducing the advantage gained by using a lessexpensive feed material. In addition, some oxygenates, such as vinylacetate or acrylic acid, are also useful chemicals and can be used aspolymer building blocks.

Recently, attempts have been made to use pyrolysis to convert naturalgas to ethylene. U.S. Pat. No. 7,183,451 discloses heating natural gasto a temperature at which a fraction is converted to hydrogen and ahydrocarbon product such as acetylene or ethylene. The product stream isthen quenched to stop further reaction and subsequently reacted in thepresence of a catalyst to form liquids to be transported. The liquidsultimately produced include naphtha, gasoline, or diesel. While thismethod may be effective for converting a portion of natural gas toacetylene or ethylene, it is estimated that this approach will provideonly about a 40% yield of acetylene from a methane feed stream. While ithas been identified that higher temperatures in conjunction with shortresidence times can increase the yield, technical limitations preventfurther improvement to this process in this regard.

While the foregoing traditional pyrolysis systems provide solutions forconverting ethane and propane into other useful hydrocarbon products,they have proven either ineffective or uneconomical for convertingmethane into these other products, such as, for example ethylene. WhileMTO technology is promising, these processes can be expensive due to theindirect approach of forming the desired product. Due to continuedincreases in the price of feeds for traditional processes, such asethane and naphtha, and the abundant supply and corresponding low costof natural gas and other methane sources available, for example the morerecent accessibility of shale gas, it is desirable to providecommercially feasible and cost effective ways to use methane as a feedfor producing ethylene and other useful hydrocarbons.

SUMMARY

A method for producing acetylene according to one aspect is provided.The method generally includes introducing a feed stream portion of ahydrocarbon stream including methane into a supersonic reactor. Themethod also includes pyrolyzing the methane in the supersonic reactor toform a reactor effluent stream portion of the hydrocarbon streamincluding acetylene. The method further includes treating at least aportion of the hydrocarbon stream in a process for producing highervalue products.

The present invention includes a process for converting the acetylene toaromatic compounds. The acetylene stream is passed to an acetyleneenrichment unit to generate an enriched acetylene stream. The enrichedacetylene stream is passed to a cyclization and aromatization reactoroperated at cyclization and aromatization reaction conditions togenerate an aromatics effluent stream.

In one embodiment, catalysts for the cyclization process includeorganometallic complexes.

In one embodiment, the invention includes passing the acetylene streamto a reactor to generate an effluent stream comprising dienes. Thedienes are passed to a cyclization reactor to generate a process streamhaving cyclooctadienes and cyclotrienes.

Other objects, advantages and applications of the present invention willbecome apparent to those skilled in the art from the following detaileddescription and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side cross-sectional view of a supersonic reactor inaccordance with various embodiments described herein; and

FIG. 2 is a schematic view of a system for converting methane intoacetylene and other hydrocarbon products in accordance with variousembodiments described herein.

DETAILED DESCRIPTION

One proposed alternative to the previous methods of producinghydrocarbon products that has not gained much commercial tractionincludes passing a hydrocarbon feedstock into a supersonic reactor andaccelerating it to supersonic speed to provide kinetic energy that canbe transformed into heat to enable an endothermic pyrolysis reaction tooccur. Variations of this process are set out in U.S. Pat. Nos.4,136,015 and 4,724,272, and Russian Patent No. SU 392723A. Theseprocesses include combusting a feedstock or carrier fluid in anoxygen-rich environment to increase the temperature of the feed andaccelerate the feed to supersonic speeds. A shock wave is created withinthe reactor to initiate pyrolysis or cracking of the feed. Inparticular, the hydrocarbon feed to the reactor comprises a methanefeed. The methane feed is reacted to generate an intermediate processstream which is then further processed to generate a hydrocarbon productstream. A particular hydrocarbon product stream of interest is one thatcomprises aromatics. Aromatic compounds are important precursors formany commercial products ranging from detergents to plastics to higheroctane fuels.

More recently, U.S. Pat. Nos. 5,219,530 and 5,300,216 have suggested asimilar process that utilizes a shock wave reactor to provide kineticenergy for initiating pyrolysis of natural gas to produce acetylene.More particularly, this process includes passing steam through a heatersection to become superheated and accelerated to a nearly supersonicspeed. The heated fluid is conveyed to a nozzle which acts to expand thecarrier fluid to a supersonic speed and lower temperature. An ethanefeedstock is passed through a compressor and heater and injected bynozzles to mix with the supersonic carrier fluid to turbulently mixtogether at a Mach 2.8 speed and a temperature of about 427° C. Thetemperature in the mixing section remains low enough to restrictpremature pyrolysis. The shockwave reactor includes a pyrolysis sectionwith a gradually increasing cross-sectional area where a standing shockwave is formed by back pressure in the reactor due to flow restrictionat the outlet. The shock wave rapidly decreases the speed of the fluid,correspondingly rapidly increasing the temperature of the mixture byconverting the kinetic energy into heat. This immediately initiatespyrolysis of the ethane feedstock to convert it to other products. Aquench heat exchanger then receives the pyrolized mixture to quench thepyrolysis reaction.

Methods and systems for converting hydrocarbon components in methanefeed streams using a supersonic reactor are generally disclosed. As usedherein, the term “methane feed stream” includes any feed streamcomprising methane. The methane feed streams provided for processing inthe supersonic reactor generally include methane and form at least aportion of a process stream that includes at least one contaminant. Themethods and systems presented herein remove or convert the contaminantin the process stream and convert at least a portion of the methane to adesired product hydrocarbon compound to produce a product stream havinga reduced contaminant level and a higher concentration of the producthydrocarbon compound relative to the feed stream. By one approach, ahydrocarbon stream portion of the process stream includes thecontaminant and methods and systems presented herein remove or convertthe contaminant in the hydrocarbon stream.

The term “hydrocarbon stream” as used herein refers to one or morestreams that provide at least a portion of the methane feed streamentering the supersonic reactor as described herein or are produced fromthe supersonic reactor from the methane feed stream, regardless ofwhether further treatment or processing is conducted on such hydrocarbonstream. The “hydrocarbon stream” may include the methane feed stream, asupersonic reactor effluent stream, a desired product stream exiting adownstream hydrocarbon conversion process or any intermediate orby-product streams formed during the processes described herein. Thehydrocarbon stream may be carried via a process stream line 115, whichincludes lines for carrying each of the portions of the process streamdescribed above. The term “process stream” as used herein includes the“hydrocarbon stream” as described above, as well as it may include acarrier fluid stream, a fuel stream, an oxygen source stream, or anystreams used in the systems and the processes described herein. Theprocess stream may be carried via a process stream line 115, whichincludes lines for carrying each of the portions of the process streamdescribed above.

Prior attempts to convert light paraffin or alkane feed streams,including ethane and propane feed streams, to other hydrocarbons usingsupersonic flow reactors have shown promise in providing higher yieldsof desired products from a particular feed stream than other moretraditional pyrolysis systems. Specifically, the ability of these typesof processes to provide very high reaction temperatures with very shortassociated residence times offers significant improvement overtraditional pyrolysis processes. It has more recently been realized thatthese processes may also be able to convert methane to acetylene andother useful hydrocarbons, whereas more traditional pyrolysis processeswere incapable or inefficient for such conversions.

The majority of previous work with supersonic reactor systems, however,has been theoretical or research based, and thus has not addressedproblems associated with practicing the process on a commercial scale.In addition, many of these prior disclosures do not contemplate usingsupersonic reactors to effectuate pyrolysis of a methane feed stream,and tend to focus primarily on the pyrolysis of ethane and propane. Oneproblem that has recently been identified with adopting the use of asupersonic flow reactor for light alkane pyrolysis, and morespecifically the pyrolysis of methane feeds to form acetylene and otheruseful products therefrom, includes negative effects that particularcontaminants in commercial feed streams can create on these processesand/or the products produced therefrom. Previous work has not consideredthe need for product purity, especially in light of potential downstreamprocessing of the reactor effluent stream. Product purity can includethe separation of several products into separate process streams, andcan also include treatments for removal of contaminants that can affecta downstream reaction, and downstream equipment.

In accordance with various embodiments disclosed herein, therefore,processes and systems for converting the methane to a product stream arepresented. The methane is converted to an intermediate process streamcomprising acetylene. The intermediate process stream is converted to asecond process stream comprising either a hydrocarbon product, or asecond intermediate hydrocarbon compound. The processing of theintermediate acetylene stream can include purification or separation ofacetylene from by-products.

The removal of particular contaminants and/or the conversion ofcontaminants into less deleterious compounds has been identified toimprove the overall process for the pyrolysis of light alkane feeds,including methane feeds, to acetylene and other useful products. In someinstances, removing these compounds from the hydrocarbon or processstream has been identified to improve the performance and functioning ofthe supersonic flow reactor and other equipment and processes within thesystem. Removing these contaminants from hydrocarbon or process streamshas also been found to reduce poisoning of downstream catalysts andadsorbents used in the process to convert acetylene produced by thesupersonic reactor into other useful hydrocarbons, for examplehydrogenation catalysts that may be used to convert acetylene intoethylene. Still further, removing certain contaminants from ahydrocarbon or process stream as set forth herein may facilitate meetingproduct specifications.

In accordance with one approach, the processes and systems disclosedherein are used to treat a hydrocarbon process stream, to remove acontaminant therefrom and convert at least a portion of methane toacetylene. The hydrocarbon process stream described herein includes themethane feed stream provided to the system, which includes methane andmay also include ethane or propane. The methane feed stream may alsoinclude combinations of methane, ethane, and propane at variousconcentrations and may also include other hydrocarbon compounds. In oneapproach, the hydrocarbon feed stream includes natural gas. The naturalgas may be provided from a variety of sources including, but not limitedto, gas fields, oil fields, coal fields, fracking of shale fields,biomass, and landfill gas. In another approach, the methane feed streamcan include a stream from another portion of a refinery or processingplant. For example, light alkanes, including methane, are oftenseparated during processing of crude oil into various products and amethane feed stream may be provided from one of these sources. Thesestreams may be provided from the same refinery or different refinery orfrom a refinery off gas. The methane feed stream may include a streamfrom combinations of different sources as well.

In accordance with the processes and systems described herein, a methanefeed stream may be provided from a remote location or at the location orlocations of the systems and methods described herein. For example,while the methane feed stream source may be located at the same refineryor processing plant where the processes and systems are carried out,such as from production from another on-site hydrocarbon conversionprocess or a local natural gas field, the methane feed stream may beprovided from a remote source via pipelines or other transportationmethods. For example a feed stream may be provided from a remotehydrocarbon processing plant or refinery or a remote natural gas field,and provided as a feed to the systems and processes described herein.Initial processing of a methane stream may occur at the remote source toremove certain contaminants from the methane feed stream. Where suchinitial processing occurs, it may be considered part of the systems andprocesses described herein, or it may occur upstream of the systems andprocesses described herein. Thus, the methane feed stream provided forthe systems and processes described herein may have varying levels ofcontaminants depending on whether initial processing occurs upstreamthereof.

In one example, the methane feed stream has a methane content rangingfrom about 65 mol-% to about 100 mol-%. In another example, theconcentration of methane in the hydrocarbon feed ranges from about 80mol-% to about 100 mol-% of the hydrocarbon feed. In yet anotherexample, the concentration of methane ranges from about 90 mol-% toabout 100 mol-% of the hydrocarbon feed.

In one example, the concentration of ethane in the methane feed rangesfrom about 0 mol-% to about 35 mol-% and in another example from about 0mol-% to about 10 mol-%. In one example, the concentration of propane inthe methane feed ranges from about 0 mol-% to about 5 mol-% and inanother example from about 0 mol-% to about 1 mol-%.

The methane feed stream may also include heavy hydrocarbons, such asaromatics, paraffinic, olefinic, and naphthenic hydrocarbons. Theseheavy hydrocarbons if present will likely be present at concentrationsof between about 0 mol-% and about 100 mol-%. In another example, theymay be present at concentrations of between about 0 mol-% and 10 mol-%and may be present at between about 0 mol-% and 2 mol-%.

In one embodiment of the present invention, the process for convertingmethane to aromatics include generating an acetylene stream through thepyrolysis of methane to generate an effluent stream having acetylene.The effluent stream is passed to cyclization reactor, where theacetylene is reacted to generate an aromatics effluent stream. Thearomatics effluent stream can comprise benzene, toluene, xylenes, andC8+ aromatics. The effluent stream comprising aromatics can be passed toan aromatics recovery unit to generate a benzene stream, a toluenestream, and a C8+ aromatics stream. In one aspect of this embodiment,the acetylene stream is passed to an acetylene enrichment zone, toremove carbon oxides, and some of the nitrogen from the acetyleneeffluent stream.

In one embodiment, the process includes enriching the acetylene streamfrom the supersonic reactor to generate an enriched acetylene stream.The acetylene stream is split into at least two portions, with a firstportion passed to a butadiene reaction unit to generate an effluentstream comprising butadiene. The butadiene effluent stream and a secondportion of the acetylene effluent stream is passed to the cyclizationand aromatization reactor to generate an aromatics effluent stream.

The cyclization, and aromatization process is carried out over acatalyst. The catalyst for cyclization and aromatization comprises ametal on a support. The support comprises a material to dispersecatalytic metals and can be comprise alumina, silica alumina, titania,zirconia, mixtures of oxides of Al, Si, Ti, Zr in any combination,zeolitic materials, non-zeolitic molecular sieves, and mixtures ofsupports. The catalyst can also comprise a metal on a support, with apreferred metal being a noble metal. Catalytic metals include metalsfrom Groups 4, 5, 6, 7, 8, 9, 10 and 11 of the Periodic Table. Thesupport can include a porous material, such as an inorganic oxide or amolecular sieve, and a binder with a weight ratio from 1:99 to 99:1. Theweight ratio is preferably from about 1:9 to about 9:1. Inorganic oxidesused for support include, but are not limited to, alumina, magnesia,titania, zirconia, chromia, zinc oxide, thoria, boria, ceramic,porcelain, bauxite, silica, silica-alumina, silicon carbide, clays,crystalline zeolitic aluminasilicates, and mixtures thereof. Porousmaterials and binders are known in the art and are not presented indetail here. The metals preferably are one or more Group VIII noblemetals, and include platinum, iridium, rhodium, and palladium.Typically, the catalyst contains an amount of the metal from about 0.01%to about 2% by weight, based on the total weight of the catalyst. Thecatalyst can also include a promoter element from Group IIIA or GroupIVA. These metals include gallium, germanium, indium, tin, thallium andlead.

In one aspect of this invention, the cyclization and aromatizationcatalyst comprises an organometallic complex. Examples of selectedcatalysts include organometallic catalysts made from noble metalcomplexes, and nickel complexes.

In one embodiment, the process includes passing the acetylene to areactor to generate dienes. This can include dimerization orpolymerization reactors to generate diacetylene compounds, orpolyacetylene compounds. The acetylene compounds can be hydrogenated togenerate a process stream comprising dienes. This would be carried outin a hydrogenation reactor under mild hydrogenation conditions to limitthe hydrogenation of the acetylene compounds. The effluent streamcomprising dienes is passed to the cyclization and aromatization reactorin the presence of an organometallic catalyst to generate an effluentstream comprising 1,5 cyclooctadiene. In another embodiment, the processconditions are controlled to react the dienes to generate an effluentstream comprising 1,5,9 cyclododeatriene.

In one embodiment, the process includes converting methane in asupersonic reactor to an effluent stream comprising acetylene. Theeffluent stream is passed to a hydrogenation reactor to generate ahydrogenation effluent stream. The hydrogenation effluent stream ispassed to a cyclization and aromatization reactor to generate anaromatics effluent stream.

The hydrogenation effluent stream comprises olefins, and the olefins canbe further processed to generate a feed to the cyclization andaromatization reaction unit. The olefins can be further processed bypassing the stream comprising olefins to an oligomerization unit togenerate an oligomerization effluent stream comprising C3+ olefins. Thelarger olefins in the oligomerization effluent stream are passed to thecyclization and aromatization reactor to generate the aromatics effluentstream. The hydrogenation reactor includes a catalyst comprising a metalon a support, wherein a preferred metal is a noble metal.

Hydrogenation reactors comprise a hydrogenation catalyst, and areoperated at hydrogenation conditions to hydrogenate unsaturatedhydrocarbons. Hydrogenation catalysts typically comprise a hydrogenationmetal on a support, wherein the hydrogenation metal is preferablyselected from a Group VIII metal in an amount between 0.01 and 2 wt. %of the catalyst. Preferably the metal is platinum (Pt), palladium (Pd),or a mixture thereof. The support is preferably a molecular sieve, andcan include zeolites such as zeolite beta, MCM-22, MCM-36, mordenite,faujasites such as X-zeolites and Y-zeolites, including B-Y-zeolites andUSY-zeolites; non-zeolitic solids such as silica-alumina, sulfatedoxides such as sulfated oxides of zirconium, titanium, or tin, mixedoxides of zirconium, molybdenum, tungsten, phosphorus and chlorinatedaluminium oxides or clays. Preferred supports are zeolites, includingmordenite, zeolite beta, faujasites such as X-zeolites and Y-zeolites,including BY-zeolites and USY-zeolites. Mixtures of solid supports canalso be employed.

In one embodiment, the present invention can integrate the aromatizationwith a benzene alkylation unit to generate an effluent stream comprisingalkylaryl compounds.

The process for forming acetylene from the methane feed stream describedherein utilizes a supersonic flow reactor for pyrolyzing methane in thefeed stream to form acetylene. The supersonic flow reactor may includeone or more reactors capable of creating a supersonic flow of a carrierfluid and the methane feed stream and expanding the carrier fluid toinitiate the pyrolysis reaction. In one approach, the process mayinclude a supersonic reactor as generally described in U.S. Pat. No.4,724,272, which is incorporated herein by reference, in their entirety.In another approach, the process and system may include a supersonicreactor such as described as a “shock wave” reactor in U.S. Pat. Nos.5,219,530 and 5,300,216, which are incorporated herein by reference, intheir entirety. In yet another approach, the supersonic reactordescribed as a “shock wave” reactor may include a reactor such asdescribed in “Supersonic Injection and Mixing in the Shock Wave Reactor”Robert G. Cerff, University of Washington Graduate School, 2010.

While a variety of supersonic reactors may be used in the presentprocess, an exemplary reactor 5 is illustrated in FIG. 1. Referring toFIG. 1, the supersonic reactor 5 includes a reactor vessel 10 generallydefining a reactor chamber 15. While the reactor 5 is illustrated as asingle reactor, it should be understood that it may be formed modularlyor as separate vessels. A combustion zone or chamber 25 is provided forcombusting a fuel to produce a carrier fluid with the desiredtemperature and flowrate. The reactor 5 may optionally include a carrierfluid inlet 20 for introducing a supplemental carrier fluid into thereactor. One or more fuel injectors 30 are provided for injecting acombustible fuel, for example hydrogen, into the combustion chamber 25.The same or other injectors may be provided for injecting an oxygensource into the combustion chamber 25 to facilitate combustion of thefuel. The fuel and oxygen are combusted to produce a hot carrier fluidstream typically having a temperature of from about 1200° C. to about3500° C. in one example, between about 2000° C. and about 3500° C. inanother example, and between about 2500° C. and 3200° C. in yet anotherexample. According to one example the carrier fluid stream has apressure of about 100 kPa or higher, greater than about 200 kPa inanother example, and greater than about 400 kPa in another example.

The hot carrier fluid stream from the combustion zone 25 is passedthrough a converging-diverging nozzle 50 to accelerate the flowrate ofthe carrier fluid to above about mach 1.0 in one example, between aboutmach 1.0 and mach 4.0 in another example, and between about mach 1.5 and3.5 in another example. In this regard, the residence time of the fluidin the reactor portion of the supersonic flow reactor is between about0.5 to 100 ms in one example, about 1 to 50 ms in another example, andabout 1.5 to 20 ms in another example.

A feedstock inlet 40 is provided for injecting the methane feed streaminto the reactor 5 to mix with the carrier fluid. The feedstock inlet 40may include one or more injectors 45 for injecting the feedstock intothe nozzle 50, a mixing zone 55, an expansion zone 60, or a reactionzone or chamber 65. The injector 45 may include a manifold, includingfor example a plurality of injection ports.

In one approach, the reactor 5 may include a mixing zone 55 for mixingof the carrier fluid and the feed stream. In another approach, no mixingzone is provided, and mixing may occur in the nozzle 50, expansion zone60, or reaction zone 65 of the reactor 5. An expansion zone 60 includesa diverging wall 70 to produce a rapid reduction in the velocity of thegases flowing therethrough, to convert the kinetic energy of the flowingfluid to thermal energy to further heat the stream to cause pyrolysis ofthe methane in the feed, which may occur in the expansion section 60and/or a downstream reaction section 65 of the reactor. The fluid isquickly quenched in a quench zone 72 to stop the pyrolysis reaction fromfurther conversion of the desired acetylene product to other compounds.Spray bars 75 may be used to introduce a quenching fluid, for examplewater or steam into the quench zone 72.

The reactor effluent exits the reactor via outlet 80 and as mentionedabove forms a portion of the hydrocarbon stream. The effluent willinclude a larger concentration of acetylene than the feed stream and areduced concentration of methane relative to the feed stream. Thereactor effluent stream may also be referred to herein as an acetylenestream as it includes an increased concentration of acetylene. Theacetylene may be an intermediate stream in a process to form anotherhydrocarbon product or it may be further processed and captured as anacetylene product stream. In one example, the reactor effluent streamhas an acetylene concentration prior to the addition of quenching fluidsranging from about 2 mol-% to about 30 mol-%. In another example, theconcentration of acetylene ranges from about 5 mol-% to about 25 mol-%and from about 8 mol-% to about 23 mol-% in another example.

In one example, the reactor effluent stream has a reduced methanecontent relative to the methane feed stream ranging from about 15 mol-%to about 95 mol-%. In another example, the concentration of methaneranges from about 40 mol-% to about 90 mol-% and from about 45 mol-% toabout 85 mol-% in another example.

In one example the yield of acetylene produced from methane in the feedin the supersonic reactor is between about 40% and about 95%. In anotherexample, the yield of acetylene produced from methane in the feed streamis between about 50% and about 90%. Advantageously, this provides abetter yield than the estimated 40% yield achieved from previous, moretraditional, pyrolysis approaches.

The invention can include an acetylene enrichment unit having an inletin fluid communication with the reactor outlet, and an outlet for aacetylene enriched effluent. One aspect of the system can furtherinclude a contaminant removal zone having an inlet in fluidcommunication with the acetylene enrichment zone outlet, and an outletin fluid communication with the hydrocarbon conversion zone inlet, forremoving contaminants that can adversely affect downstream catalysts andprocesses. One contaminant to be removed is CO to a level of less than0.1 mole-%, and preferably to a level of less than 100 ppm by vol. Anadditional aspect of the invention is where the system can include asecond contaminant removal zone having an inlet in fluid communicationwith the methane feed stream and an outlet in fluid communication withthe supersonic reactor inlet.

By one approach, the reactor effluent stream is reacted to form anotherhydrocarbon compound. In this regard, the reactor effluent portion ofthe hydrocarbon stream may be passed from the reactor outlet to adownstream hydrocarbon conversion process for further processing of thestream. While it should be understood that the reactor effluent streammay undergo several intermediate process steps, such as, for example,water removal, adsorption, and/or absorption to provide a concentratedacetylene stream, these intermediate steps will not be described indetail herein.

Referring to FIG. 2, the reactor effluent stream having a higherconcentration of acetylene may be passed to a downstream hydrocarbonconversion zone 100 where the acetylene may be converted to form anotherhydrocarbon product. The hydrocarbon conversion zone 100 may include ahydrocarbon conversion reactor 105 for converting the acetylene toanother hydrocarbon product. While FIG. 2 illustrates a process flowdiagram for converting at least a portion of the acetylene in theeffluent stream to ethylene through hydrogenation in hydrogenationreactor 110, it should be understood that the hydrocarbon conversionzone 100 may include a variety of other hydrocarbon conversion processesinstead of or in addition to a hydrogenation reactor 110, or acombination of hydrocarbon conversion processes. Similarly, itillustrated in FIG. 2 may be modified or removed and are shown forillustrative purposes and not intended to be limiting of the processesand systems described herein. Specifically, it has been identified thatseveral other hydrocarbon conversion processes, other than thosedisclosed in previous approaches, may be positioned downstream of thesupersonic reactor 5,including processes to convert the acetylene intoother hydrocarbons, including, but not limited to: alkenes, alkanes,methane, acrolein, acrylic acid, acrylates, acrylamide, aldehydes,polyacetylides, benzene, toluene, styrene, aniline, cyclohexanone,caprolactam, propylene, butadiene, butyne diol, butandiol, C2-C4hydrocarbon compounds, ethylene glycol, diesel fuel, diacids, diols,pyrrolidines, and pyrrolidones.

A contaminant removal zone 120 for removing one or more contaminantsfrom the hydrocarbon or process stream may be located at variouspositions along the hydrocarbon or process stream depending on theimpact of the particular contaminant on the product or process and thereason for the contaminants removal, as described further below. Forexample, particular contaminants have been identified to interfere withthe operation of the supersonic flow reactor 5 and/or to foul componentsin the supersonic flow reactor 5. Thus, according to one approach, acontaminant removal zone is positioned upstream of the supersonic flowreactor in order to remove these contaminants from the methane feedstream prior to introducing the stream into the supersonic reactor.Other contaminants have been identified to interfere with a downstreamprocessing step or hydrocarbon conversion process, in which case thecontaminant removal zone may be positioned upstream of the supersonicreactor or between the supersonic reactor and the particular downstreamprocessing step at issue. Still other contaminants have been identifiedthat should be removed to meet particular product specifications. Whereit is desired to remove multiple contaminants from the hydrocarbon orprocess stream, various contaminant removal zones may be positioned atdifferent locations along the hydrocarbon or process stream. In stillother approaches, a contaminant removal zone may overlap or beintegrated with another process within the system, in which case thecontaminant may be removed during another portion of the process,including, but not limited to the supersonic reactor 5 or the downstreamhydrocarbon conversion zone 100. This may be accomplished with orwithout modification to these particular zones, reactors or processes.While the contaminant removal zone 120 illustrated in FIG. 2 is shownpositioned downstream of the hydrocarbon conversion reactor 105, itshould be understood that the contaminant removal zone 120 in accordanceherewith may be positioned upstream of the supersonic flow reactor 5,between the supersonic flow reactor 5 and the hydrocarbon conversionzone 100, or downstream of the hydrocarbon conversion zone 100 asillustrated in FIG. 2 or along other streams within the process stream,such as, for example, a carrier fluid stream, a fuel stream, an oxygensource stream, or any streams used in the systems and the processesdescribed herein.

While there have been illustrated and described particular embodimentsand aspects, it will be appreciated that numerous changes andmodifications will occur to those skilled in the art, and it is intendedin the appended claims to cover all those changes and modificationswhich fall within the true spirit and scope of the present disclosureand appended claims.

The invention claimed is:
 1. A method for producing aromatics comprising: introducing a feed stream comprising methane into a supersonic reactor; pyrolyzing the methane in the supersonic shock wave reactor to form a reactor effluent stream comprising acetylene and methane acting as a diluent to the reactor effluent stream; treating the reactor effluent stream by removing carbon dioxide to a level below about 1000 wt.-ppm of the hydrocarbon stream to form a treated reactor effluent stream comprising acetylene and methane; splitting the treated reactor effluent stream comprising acetylene and methane into a first portion and a second portion; passing the first portion of the treated effluent stream comprising acetylene and methane to a butadiene reaction unit to convert acetylene to an effluent stream comprising butadiene; and passing the butadiene effluent stream and a second portion of the treated effluent stream comprising acetylene and methane to a cyclization and aromatization reactor including a group VIII metal on a support to react the butadiene and acetylene to form aromatic compounds including benzene, toluene, and a C8+aromatics.
 2. The method of claim 1, wherein pyrolyzing the methane includes accelerating the hydrocarbon stream to a velocity of between about mach 1.0 and about mach 4.0 and slowing down the hydrocarbon stream to increase the temperature of the hydrocarbon process stream.
 3. The method of claim 1, wherein pyrolyzing the methane includes heating the methane to a temperature of between about 1200° C. and about 3500° C. for a residence time of between about 0.5 ms and about 100 ms.
 4. The method of claim 1, wherein the hydrocarbon stream includes a methane feed stream portion upstream of the supersonic reactor comprising natural gas.
 5. The method of claim 1, further comprising passing the methane feed to a methane enrichment zone positioned upstream of the supersonic reactor to remove at least some of the non-methane compounds from the feed stream prior to introducing the feed stream into the supersonic reactor.
 6. The method of claim 1 further comprising: passing the reactor effluent stream comprising acetylene and methane to an acetylene purification unit to generate an enriched acetylene stream and a residual stream comprising CO and H₂; and passing the enriched acetylene stream to the splitting step.
 7. The method of claim 1 further comprising passing the aromatic effluent stream to an aromatics product recovery unit to generate a benzene stream, a toluene stream, and a C8+aromatics stream.
 8. The method of claim 1 wherein the catalyst comprises a Group VIII metal on an acid support, wherein the support is selected from alumina, silica alumina, zeolitic materials, and mixtures thereof. 